Topology optimization of clutch drive plate for commercial vehicles

Abstract

The drive plate is one of the main components of the clutch disc which transmitsthe torque from engine to transmission. For commercial vehicle applications, thedrive plate works under immense torsional forces thanks to high engine torquevalues. Therefore, high durability is expected during the operational life of theclutch disc drive plate. On the other hand, the lightweight of the vehiclecomponents has an important role in CO2 emission standards. To be able to assurethis regulation, companies conduct studies for decreasing the vehicle mass. In thisstudy, the drive plate's 3D CAD data is created based on the current design byusing CATIA solid creation software. Finite Element Analysis (FEA) was carriedout in a statical analysis tool and to be verified for real-life working conditions.The topology optimization was performed using CAE software (ANSYS) in orderto reduce the weight of the drive plate without compromising on mechanicaldurability. The optimized design was proposed based on topology optimizationoutputs. The strength of the proposed design was investigated by using FEAanalysis and results are compared to the acceptance criteria of the material. Theoptimized geometry is equally durable and lighter in weight compared to theexisting model. Mass was decreased %18 without compromising mechanicaldurability